Project duration: 18 months (phased delivery)
Project scope:
- Design and development of seven bottle variants across round shape, square shape, and specially designed premium pack sizes
- Manufacturing of moulds for high-speed linear blowers in 8, 10, and 12-cavity configurations, totalling 80 cavities
- Phased manufacturing and delivery aligned to the customer’s rollout schedule over 18 months
Project Synopsis
The objective of this project was to design and manufacture moulds for a leading regional beverage company in Maharashtra, operating sophisticated high-speed linear blowers, across a wide pack range: 3 packs of round bottles; 3 packs of square bottles; and a specially designed premium small pack size. The customer’s equipment ran high-precision 8, 10, and 12-cavity configurations, demanding the same rigour in mould engineering that we bring to our largest global accounts.
This project reflects how we work: while much of our business comes from global and national brands, we partner just as closely with regional companies when the scale of the requirement and the sophistication of the equipment call for it.
Bottle Designing, Tested to the Last Detail
- Each of the seven bottle designs was developed in close collaboration with the customer, going through multiple rounds of design iteration before finalisation.
- Beyond standard 3D modelling, this project included a unit cavity trial for validation — building and testing a single-cavity mould to confirm the design before committing to full multi-cavity production.
- This extra layer of validation meant design issues were caught and resolved early, rather than surfacing after moulds for all cavities had already been manufactured
Engineering for Exact Machine Compatibility
- With three different bottle shapes running across three different cavity configurations (8, 10, and 12), every mould had to be engineered precisely to match its specific blowing equipment as well as its bottle design.
- On sophisticated high-speed equipment, there is little tolerance for approximation — moulds need to be engineered to the same fit and finish standards the machine itself was built to, so they run reliably at full speed from the first cycle.
- These blowers typically produce 250 to 300 bottles per minute, translating to an actual blowing time of less than 1 second for 10 bottles in a line
- Meeting this standard consistently was key to building the kind of trust that leads to repeat business.
Phased Delivery Across 18 Months
- The full order of 80 cavities was manufactured and delivered in multiple phases over 18 months, aligned with the customer’s own rollout of bottle variants and machine lines.
- This phased approach let the customer bring pack sizes into production progressively, rather than waiting for the entire multi-shape, multi-cavity order to be completed at once.
- Consistent quality and compatibility across every phase reinforced the customer’s confidence in scaling this partnership further.
Awanti Polymoulds Pvt. Ltd. | Pune, India | www.awantipolymoulds.com
